Erosion-and-sediment-control block and method of manufacture

ABSTRACT

In one aspect, the present invention relates to an erosion-and-sediment-control system. The erosion-and-sediment-control system includes a sleeve having a substantially-flat bottom surface and a fiber matrix disposed within, and substantially filling, the sleeve. A flap is formed at a first end of the sleeve. The substantially-flat bottom surface resists movement due to wave action and currents.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to, and incorporates by reference theentire disclosure of, U.S. Provisional Patent Application No.61/684,169, filed Aug. 17, 2012.

BACKGROUND

1. Field of the Invention

The present application relates generally toerosion-and-sediment-control systems, and more particularly, but not byway of limitation, to elongate, fiber-filled,erosion-and-sediment-control blocks having a substantially-flat bottomsurface for increased contact with a subgrade.

2. History of the Related Art

Erosion-control devices, such as blankets and logs, are commonlyutilized to reduce soil erosion and runoff from erosion-prone areas suchas highway embankments or water drainage ditches (referred to as a“subgrade”). Erosion-control devices incorporate a variety of designsand may be manufactured from a variety of materials. For example,erosion-control blankets include a fibrous matting in which outer layersof netting or other material are commonly used to form an envelope orcovering about a fibrous interior filler layer.

Erosion-control logs typically utilize fibers packaged within anelongate bag-type structure for reducing hydraulic energy and filteringsediment-laden runoff. A fibrous matrix is contained within the elongatebag-type structure. The erosion-control log is very porous, allowingwater to pass through the fibrous matrix, which progressively slowsvelocity and filters sediment as the water passes through theerosion-control log's diameter. Erosion-control logs of this type arelightweight and generally require no trenching. In addition,erosion-control logs present few disposal hassles and may be reusablewhile holding their shape. Erosion-control logs are commonly used inplace of straw or hay bale checks, which have been shown to be less thancapable of prolonged use in heavy rains. Silt fences are anothercommonly utilized erosion-control device. Silt fences are generallyprone to being knocked down when rain or strong winds are present, orwhen run over by vehicles.

The time required to pick up lose hay fibers from hay bales and/or toremove worn out, or dysfunctional silt fences imposes increased expenseto contractors. Further, federal, state, and municipal regulations areincreasingly requiring erosion control around construction sites.

SUMMARY

The present application relates generally toerosion-and-sediment-control systems, and more particularly, but not byway of limitation, to erosion-and-sediment-control blocks having asubstantially-flat bottom surface for intimate contact with a subgrade.In one aspect, the present invention relates to anerosion-and-sediment-control system. The erosion-and-sediment-controlsystem includes a sleeve having a substantially-flat bottom surface anda fiber matrix disposed within, and substantially filling, the sleeve. Aflap is formed at a first end of the sleeve. The substantially-flatbottom surface resists movement due to wave action and currents.

In another aspect, the present invention relates to a method ofinstalling an erosion-and-sediment-control system. The method includespositioning a first erosion-and-sediment-control block, having asubstantially-flat bottom surface, along a shoreline of a body of water.A plurality of stakes are arranged on opposite sides of the firsterosion-and-sediment-control block. A tether is stretched between theplurality of stakes thereby securing the firsterosion-and-sediment-control block. The substantially-flat bottomsurface resists movement due to wave action and currents present in thebody of water.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and forfurther objects and advantages thereof, reference may now be had to thefollowing description taken in conjunction with the accompanyingdrawings in which:

FIG. 1 is the perspective view of an erosion-and-sediment-control blockaccording to an exemplary embodiment;

FIG. 2 is a perspective view of a junction between adjacenterosion-and-sediment-control blocks according to an exemplaryembodiment;

FIG. 3A is a top view illustrating installation of anerosion-and-sediment-control block according to an exemplary embodiment;

FIGS. 3B-3E are illustrations of installation of anerosion-and-sediment-control block according to an exemplary embodiment;

FIG. 4 is a flow diagram of a process for installing anerosion-and-sediment-control system according to an exemplaryembodiment;

FIGS. 5A-5B are cross-sectional views of arrangements of anerosion-and-sediment-control block according to an exemplary embodiment;

FIG. 5C is a front view of a stacked erosion-and-sediment-control systemaccording to an exemplary embodiment;

FIG. 5D is an illustration of an arrangement of anerosion-and-sediment-control block according to an exemplary embodiment;

FIG. 6A is a schematic diagram of a system for manufacturing anerosion-and-sediment-control block according to an exemplary embodiment;

FIGS. 6B-6D are illustrations of a system for manufacturing anerosion-and-sediment-control block according to exemplary embodiment;and

FIG. 7 is a flow diagram of a process for manufacturing anerosion-and-sediment-control block according to exemplary embodiment.

DETAILED DESCRIPTION

Various embodiments of the present invention will now be described morefully with reference to the accompanying drawings. The invention may,however, be embodied in many different forms and should not be construedas limited to the embodiments set forth herein.

FIG. 1 is a perspective view of an erosion-and-sediment-control blockaccording to an exemplary embodiment. An erosion-and-sediment-controlblock 100 includes a sleeve 102 filled with a fiber matrix 104. Thesleeve 102 has a generally rectangular cross-sectional shape including asubstantially-flat bottom surface 108. The substantially-flat bottomsurface 108 allows the erosion-and-sediment-control block 100 to haveincreased intimate contact with a subgrade (not shown) and preventsshifting of the erosion-and-sediment-control block 100 due to currentsor wave action present in, for example, a body of water (not shown). Ina typical embodiment, the sleeve 102 is constructed from a biodegradablematerial such as, for example, cotton, jute, or other appropriatematerial; however, in other embodiments, the sleeve 102 may beconstructed from a synthetic material. A flap 106 is disposed at one endof the erosion-and-sediment-control block 100. In a typical embodiment,the flap 106 is formed of the same material as the sleeve 102; however,in alternative embodiments, other materials may be utilized. The flap106 allows formation of a seamless joint between theerosion-and-sediment-control block 100 and an adjacenterosion-and-sediment-control block (not shown).

Still referring to FIG. 1, the fiber matrix 104 is entirely contained inthe sleeve 102. In a typical embodiment, the fiber matrix 104 includescurled interlocking fibers with barbed edges (not shown). The barbededges cause the curled interlocking fibers to cling to each other thuslending strength and stability to the erosion-and-sediment-control block100. The fiber matrix 104 may be constructed from, for example, woodwool. Wood wool, also known as “excelsior,” is a product constructedfrom wood shavings cut from logs. In a typical embodiment, the fibermatrix 104 is constructed from wood wool of, for example, Great LakesAspen, or other appropriate wood. The fiber matrix 104 is porous, thusallowing water and other fluids to easily pass therethrough. The curledinterlocking fibers progressively slow velocity and filter sediment asthe water or other fluid passes through a width of theerosion-and-sediment-control block 100. In a typical embodiment, thefiber matrix 104 is biocompatible and able to foster vegetation growth.

FIG. 2 is a perspective view of a junction between adjacenterosion-and-sediment-control blocks. As shown in FIG. 2, a firsterosion-and-sediment-control block 202 is positioned to abut a seconderosion-and-sediment-control block 204 in, for example, an end-to-endfashion; however, in alternative embodiments, other arrangements couldbe utilized. A flap 206 extends from a first end 205 of the firsterosion-and-sediment-control block 202. As shown in FIG. 2C, the flap206 is stretched over a second end 207 of the seconderosion-and-sediment-control block 204 and secured thereto. As shown inFIG. 2D, the flap 206 thus creates a seamless joint between he firsterosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204. Although FIG. 2 depicts thefirst erosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204, one skilled in the art willrecognize that, in other embodiments, any number oferosion-and-sediment-control blocks may be utilized.

FIG. 3A is a top view illustrating installation of anerosion-and-sediment-control system according to an exemplaryembodiment. The erosion-and-sediment-control system 300 includes thefirst erosion-and-sediment-control block 202 positioned to abut thesecond erosion-and-sediment-control block 204 and a plurality of stakes302 arranged alongside the first erosion-and-sediment-control block 202and the second erosion-and-sediment-control block 204. The firsterosion-and-sediment-control block 202 is positioned near a shore lineof a body of water 308 such as, for example, a lake, a river, a stream,or other body of water. In a typical embodiment, a long axis 306 of thefirst erosion-and-sediment-control block 202 is positioned generallyparallel to a direction of a current 310 of the body of water 308 andgenerally perpendicular to a direction of wave travel 312 in the body ofwater 308.

Still referring to FIG. 3A, the second erosion-and-sediment-controlblock 204 is positioned to abut the first erosion-and-sediment-controlblock 202 in an end-to-end fashion. The seconderosion-and-sediment-control block 204 is secured to the firsterosion-and-sediment-control block 202 to form a seamless joint in amanner similar to that described above with respect to FIG. 2. AlthoughFIG. 3A illustrates the erosion-and-sediment-control system 300 asincluding the first erosion-and-sediment-control block 202 and thesecond erosion-and-sediment-control block 204, one skilled in the artwill recognize that erosion-and-sediment-control systems utilizingprinciples of the invention may include any number oferosion-and-sediment-control blocks. Further,erosion-and-sediment-control systems utilizing principles of theinvention may include a single erosion-and-sediment-control block suchas, for example, the first erosion-and-sediment-control block 202.

FIGS. 3B-3E are illustrations of installation of anerosion-and-sediment-control block according to an exemplary embodiment.Referring to FIGS. 3A-3E, the plurality of stakes 302 are positioned onopposite sides of the first erosion-and-sediment-control block 202 andthe second erosion-and-sediment-control block 204. In a typicalembodiment, the plurality of stakes 302 extend into a subgrade (notexplicitly shown) approximately twenty-four inches. As shown in FIG. 3B,a rope 304 is wrapped around, and stretched between, each stake of theplurality of stakes 302 thus securing the firsterosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204 to the subgrade. In a typicalembodiment, the rope 304 is stretched between each stake of theplurality of stakes 302 to form an approximate “saw-tooth” pattern;however, other securement patterns could be utilized. Thesubstantially-flat bottom surface 108 (shown in FIG. 1) providesintimate contact with the subgrade. The substantially-flat bottomsurface 108 resists rolling due to current and wave action within thebody of water 308. As shown in FIG. 3C, a plurality of pilot holes 314are formed in the first erosion-and-sediment-control block 202 and thesecond erosion-and-sediment-control block 204. As shown in FIG. 3D, theplurality of pilot holes 314 may be formed via, for example, driving acylindrical rod through at least one of the firsterosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204. As shown in FIG. 3E, in atypical embodiment, vegetation may be planted in the plurality of pilotholes 314. During operation, the fiber matrix 104 (illustrated inFIG. 1) allows the vegetation to take root. The fiber matrix 104 alsoprevents erosion of the subgrade, which is harmful to vegetative growth.As the vegetation grows and becomes capable of preventing erosion of thesubgrade, the erosion-and-sediment-control system 300 breaks down andbiodegrades. Thus, in a typical embodiment, once installed, theerosion-and-sediment-control system 300 does not need to be removed.

FIG. 4 is a flow diagram of a process for installing anerosion-and-sediment-control system according to an exemplaryembodiment. A process 400 begins at step 402. At step 404 anerosion-and-sediment-control block such as, for example, the firsterosion-and-sediment-control block 202, is positioned along a shore lineof the body of water 308. At step 406, the firsterosion-and-sediment-control block 202 is arranged such that the longaxis 306 of the first erosion-and-sediment-control block 202 isgenerally perpendicular to the direction of wave travel 312. At step407, the second erosion-and-sediment-control block 204 is positioned toabut the first erosion-and-sediment-control block 202 in an end-to-endfashion. At step 408, a seamless joint is formed between the firsterosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204. At step 410, the plurality ofstakes 302 are arranged on opposite sides of the firsterosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204. At step 411, the plurality ofstakes 302 are driven into the subgrade until a top of the plurality ofstakes 302 is approximately 4 inches above a top surface of the firsterosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204.

Still referring to FIG. 4, at step 412, the rope 304 is wrapped around,and stretched between, each stake of the plurality of stakes 302 therebysecuring the first erosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204 to the subgrade. At step 413, theplurality of stakes 302 are driven into the subgrade until the top ofthe plurality of stakes 302 is approximately flush with the top surfaceof the first erosion-and-sediment-control block 202 and the seconderosion-and-sediment-control block 204. At step 414, a plurality ofpilot holes 314 are formed in the first erosion-and-sediment-controlblock 202 and the second erosion-and-sediment-control block 204. At step416, vegetation is secured within the plurality of pilot holes 314. Theprocess 400 ends at step 418. Although the process 400 describesutilizing the first erosion-and-sediment-control block 202 and thesecond erosion-and-sediment-control block 204, one skilled in the artwill recognize that processes utilizing principles of the invention mayutilize any number of erosion-and-sediment-control blocks including asingle erosion-and-sediment-control block. In embodiments, utilizing asingle erosion-and-sediment-control block, steps 407-408 are omitted.

FIGS. 5A-5B are cross-sectional views of various arrangements of anerosion-and-sediment-control block according to exemplary embodiments.As shown in FIG. 5A, a trench 502 is formed to accommodate theerosion-and-sediment-control block 500. A secondary erosion-controldevice 503 such as, for example, an erosion control net or blanket isutilized in conjunction with the erosion-and-sediment-control block 500.As illustrated in FIG. 5A, such an arrangement is advantageous inapplications where a subgrade 501 is sloped. In a typical embodiment,when the subgrade 501 is sloped less than or approximately equal to 4%,the trench 502 extends to a depth of approximately one-half of a heightof the erosion-and-sediment-control block 500. When the subgrade 501 issloped greater than or approximately equal to 5%, the trench 502 extendsto a depth of approximately two-thirds of the height of theerosion-and-sediment-control block 500. In various embodiments, a seconderosion-and-sediment-control block (not shown) may be stacked above theerosion-and-sediment-control block 500. Such an arrangement is necessarywhen the erosion-and-sediment-control block 500 is not taller than amean high-water level of a body of water 508.

FIGS. 5B illustrates use of multiple rows oferosion-and-sediment-control blocks. As illustrated in FIG. 5B, a firsttrench 552 is formed in a subgrade 560 adjacent to a shoreline 555 and asecond trench 554 is formed uphill of the first trench 552. A firsterosion-and-sediment-control block 556 is placed in the first trench 552and the second erosion-and-sediment-control block 558 is placed in thesecond trench 554 thus creating a terraced subgrade 560. FIG. 5D is aphotographic illustration of the arrangement described with respect toFIG. 5B.

FIG. 5C is a front view of a stacked erosion-and-sediment-control systemaccording to an exemplary embodiment. An erosion-and-sediment-controlsystem 570 includes a first erosion-and-sediment-control block 572, asecond erosion-and-sediment-control block 574, and a thirderosion-and-sediment-control block 576. As illustrated in FIG. 5C, thethird erosion-and-sediment-control block 576 is arranged to span a jointformed between the first erosion-and-sediment-control block 572 and thesecond erosion-and-sediment-control block 574. Such an arrangementreduces unfiltered passage of water through the firsterosion-and-sediment-control block 572, the seconderosion-and-sediment-control block 574, and the thirderosion-and-sediment-control block 576.

FIGS. 6A is a schematic diagram of a system for manufacturing anerosion-and-sediment-control block according to exemplary embodiment.FIGS. 6B-6D are illustrations of a system for manufacturing anerosion-and-sediment-control block according to exemplary embodiment.Referring to FIGS. 6A-6D, a manufacturing system 600 includes a table602 arranged adjacent to a press 604. As shown in FIGS. 6B and 6C, thetable 602 may be a conveyor table. As shown in FIG. 6C, duringoperation, the sleeve 102 is arranged around an opening 603 of the press604. In a typical embodiment, a cone 607 (shown in FIG. 6D) may beattached to the opening 603 to assist positioning of the sleeve 102. Afirst end 605 of the sleeve 102 is closed through a process such as, forexample, tying, sewing, or other appropriate closure method. The fibermatrix 104 is pressed through the opening 603 by the press 604. Theopening 603 imparts a generally rectangular cross-sectional shape to thefiber matrix 104. The generally rectangular cross-sectional shape of thefiber matrix 104 causes the sleeve 102 to also assume a generallyrectangular cross-sectional shape. The fiber matrix 104 fills the sleeve102 causing the sleeve 102 to extend down the table 602 in a directionaway from the opening 603. When the sleeve 102 reaches a desired length,the sleeve 102 is cut thus forming an erosion-and-sediment-control blocksuch as, for example, the erosion-and-sediment- control block 100 (shownin FIG. 1). In a typical embodiment, the press 604 may be, for example,a hydraulic press, a pneumatic press, a mechanical press, or a manualpress.

FIG. 7 is a flow diagram of a process for manufacturing anerosion-and-sediment-control block according to exemplary embodiment. Aprocess 700 begins at step 702. At step 704, the sleeve 102 is arrangedaround the opening 603. At step 706, the first end 605 of the sleeve 102is closed around the opening 603. At step 708, the press 604 presses thefiber matrix 104 through the opening 603 into the sleeve 102. Theopening 603 imparts a generally rectangular cross-sectional shape to thefiber matrix 104. The generally rectangular cross-sectional shape of thefiber matrix 104 causes the sleeve 102 to also take on a generallyrectangular cross-sectional shape. At step 710, the fiber matrix 104fills the sleeve 102. At step 712, the sleeve 102 is cut to a desiredlength thus forming an erosion-and-sediment-control block such as, forexample, the erosion-and-sediment-control block 100. The process 700ends at step 714.

Although various embodiments of the method and system of the presentinvention have been illustrated in the accompanying Drawings anddescribed in the foregoing Specification, it will be understood that theinvention is not limited to the embodiments disclosed, but is capable ofnumerous rearrangements, modifications, and substitutions withoutdeparting from the spirit and scope of the invention as set forthherein. It is intended that the Specification and examples be consideredas illustrative only.

What is claimed is:
 1. An erosion-and-sediment-control systemcomprising: a sleeve comprising a substantially-flat bottom surface; afiber matrix disposed within, and substantially filling, the sleeve; aflap formed at a first end of the sleeve; and wherein thesubstantially-flat bottom surface resists movement due to wave actionand currents.
 2. The erosion-and-sediment-control system of claim 1,comprising: a second sleeve comprising a second substantially-flatbottom surface, the second sleeve positioned adjacent to the first endof the sleeve; a second fiber matrix disposed within, and substantiallyfilling, the sleeve; wherein the flap facilitates formation of aseamless joint between the sleeve and the second sleeve.
 3. Theerosion-and-sediment-control system of claim 2, wherein the sleeve andthe second sleeve abut each other in an end-to-end fashion.
 4. Theerosion-and-sediment-control system of claim 1, wherein the sleeve isbiodegradeable.
 5. The erosion-and-sediment-control system of claim 1,wherein the fiber matrix comprises curled interlocking fibers withbarbed edges.
 6. The erosion-and-sediment-control system of claim 5,wherein the fiber matrix is wood wool.
 7. Theerosion-and-sediment-control system of claim 1, comprising: a pluralityof stakes disposed on either side of the sleeve; a tether stretchedbetween individual stakes of the plurality of stakes, the tether and theplurality of stakes together securing the sleeve to a subgrade.
 8. Amethod of installing an erosion-and-sediment-control system, the methodcomprising: positioning a first erosion-and-sediment-control blockcomprising a substantially-flat bottom surface along a shoreline of abody of water; arranging a plurality of stakes on opposite sides of thefirst erosion-and-sediment-control block; stretching a tether betweenthe plurality of stakes thereby securing the firsterosion-and-sediment-control block; and wherein the substantially-flatbottom surface resists movement due to wave action and currents presentin the body of water.
 9. The method of claim 8, comprising forming aplurality of holes through the first erosion-and-sediment-control block.10. The method of claim 9, comprising establishing foliage within atleast one hole of the plurality of holes.
 11. The method of claim 8,comprising positioning a second erosion-and-sediment-control blockadjacent to the first erosion-and-sediment-control block, the seconderosion-and-sediment-control block abutting the firsterosion-and-sediment-control block in an end-to-end fashion.
 12. Themethod of claim 8, wherein the first erosion-and-sediment-control blockis positioned such that a long axis of the firsterosion-and-sediment-control block is generally perpendicular to adirection of wave travel.
 13. The method of claim 8, comprising forminga trench for receipt of the first erosion-and-sediment-control block.14. The method of claim 13, wherein a seconderosion-and-sediment-control block is positioned above the firsterosion-and-sediment-control block.
 15. A method of manufacturing anerosion-and-sediment-control block, the method comprising: positioning asleeve around an opening of a press; closing a first end of the sleeveso as to cover the opening; pressing, via the press, a fiber matrix intothe sleeve, the press imparting a generally rectangular shape to thefiber matrix; and cutting the sleeve.
 15. The method of claim 15,comprising attaching a cone to the opening of the press, the conefacilitating the positioning of the sleeve.
 16. The method of claim 15,wherein the closing comprises tying the first end of the sleeve.
 17. Themethod of claim 15, wherein the pressing imparts a generally rectangularshape to the erosion-and-sediment-control block.
 18. The method of claim15, wherein the cutting occurs when the sleeve reaches a desired length.19. The method of claim 15, comprising filling the sleeve with the fibermatrix.
 20. The method of claim 15, wherein the steps are performed inthe order listed.